Twist-off container plug

ABSTRACT

A container having a removable tab which creates a dispensing opening when removed and where a lateral projection on said tab can be used to reseal the tube.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a tab or plug, and more particularly to twist tab or plug for a container.

2. Related Art

Existing container caps and the like require the use of scissors or a knife in order to access the contents of the container. Often there is no mechanism for resealing, so the entire contents must be used, leading to unnecessary waste. Caps that do allow for resealing often do not seal effectively, leading to drying out and rapid deterioration of tube contents. Caps or plugs that do seal tightly are difficult to remove.

Plugs or caps are often separate components that are sometimes lost during shipping, display, or storage before use. U.S. Pat. No. 5,295,601 to Bostelman discloses a cap with a tether so that the cap does not separate from the container during use. However, this requires the separate purchase of a cap, resulting in added cost. The separate purchase of a cap also means the cap is not specifically made to fit the container for which it is used to seal. Thus there is no guarantee that the seal will be as effective as desired.

Another disadvantage of currently existing separate caps and plugs is that they may need to be separately molded.

Container tips are composed of sturdy plastic, making cutting difficult, and potentially dangerous. Further, it may take several attempts before achieving a hole of the appropriate size. For example, cutting too close to the tip edge may create an opening that is not large enough for the contents to easily flow through, leading to clogging. A cut that is too large results in too much material flowing out of the tube. There is no remedy for this, except to start over with a another tube. Finally, a hole that is too large or too small may preclude use of the resealing cap that is provided. All of these scenarios can lead to unnecessary waste and expense.

Another disadvantage in the prior art is that caps, by design, may not be properly fitted for sealing the tip hole that results from cutting. Again, this leads to degradation of tube contents. However, plugs that seal tightly can then be difficult to remove.

What is needed then is an improved tab, cap or plug that overcomes shortcomings of conventional solutions.

BRIEF SUMMARY OF THE INVENTION

The present invention is for a container having a tubular, tapered tip and a tab. The tab is removable and can be used to seal the tip. A tubular receptacle sits at the end of the tip opposite to the end at which the tab sits. The receptacle may be designed to contain a viscous substance or a suspension of a solid in a fluid matrix, such as, for example, caulk, icing, sauces, gels, lotions, soaps, a wood filler, and the like.

The tab has lateral projections which are substantially perpendicular to the axis of the tip prior to removal of the tab. Removal of the tab creates a dispensing opening in the tip. By rotating the tab 90° so that the axis of the projections is substantially parallel to the axis of the tip, the opening may be resealed using the lateral projections of the tab.

The tab also contains a joining piece. This portion of the tab is connected to the tip prior to removal of the tab. The joining piece facilitates removal of the tab once the tip has already been sealed by allowing the user to grip the piece and remove the tab.

The container and tab can be manufactured as one unit. There are several advantages to this invention where the tab is manufactured/sold as part of the container. A first advantage is that the tab is molded to fit the tip to which it is attached, resulting in an effective seal. Another advantage is that the purchase of a separate cap or tab is not required. Further, there is no danger of the plug or cap being separated from the tip and lost prior to use.

The invention is also drawn to a method of using the container and its easily removable tab to create an dispensing opening, dispense the contents of the container, and re-seal the opening.

The invention is additionally drawn to a method of manufacturing the container of the present invention by compression molding and extrusion blow molding.

Further objectives and advantages, as well as the structure and function of preferred embodiments will become apparent from a consideration of the description, drawings, and examples.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the invention will be apparent from the following, more particular description of an exemplary embodiment of the invention, as illustrated in the accompanying drawings wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.

FIG. 1 depicts an exemplary embodiment of a twist container according to the present invention, prior to opening;

FIG. 2 depicts the removable tab and top end of the tip prior to opening of the container, according to the present invention;

FIG. 3 depicts the top end of the tip and the tab when the tab has been removed, creating a dispensing opening, according to the present invention.

FIG. 4 depicts the twist tab and top end of the tip as in the present invention, once the tip has been resealed.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the invention are discussed in detail below. In describing embodiments, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected. While specific exemplary embodiments are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations can be used without parting from the spirit and scope of the invention. All references cited herein are incorporated by reference as if each had been individually incorporated.

FIG. 1 illustrates the container of the present invention. The container 100 is a one-piece construction that is compression/blow molded and is made of a plastic material such as a polyester, including polyethylene terephthalate (PET) and polyethylene naphthalate (PEN); polyolefins such as polyethylenes, and polypropylenes; and polyamides such as nylon. High density polyethylene (HDPE) is a particular example of a plastic material useful in practicing the invention. The container can be used to package a wide variety of materials, including viscous materials and suspensions such as caulk, wood filler compositions, icing, gels, sauces, lotions, soaps, and others.

The container 100 has a tubular receptacle 101 for containing the material, having a bottom end 102, a tubular sidewall 103 and a top end 104. The tubular sidewall 103 of the illustrated embodiment is circular in cross-section, such that the receptacle 101 is cylindrical. Other cross-sectional shapes can be similarly used and manufactured. Extending from the top end 104 of the tubular receptacle 101 is the tip 106, which is connected to the top end 104 of the receptacle 101 by the tip's bottom end 108. The tip 106 has a tubular sidewall 110, and a top end 112, to which the removable twist tab 114 is attached. The twist tab contains a wider joining piece 111 which is connected to the top end of the tube 112. The top end 112 of the tip is narrower than the bottom end of the tip 108 such that at least a portion of the tip between the receptacle 101 and the twist tab 114 is tapered. In the illustrated embodiment, the tip sidewall 110 is also cylindrical in shape, but other shapes can be used.

The twist tab 114 has tapered lateral projections 116. (See FIG. 2). Prior to opening, the tab 114 is connected to and seals the tip 106. In this position, the lateral projections 116 are substantially perpendicular to the tip sidewall 110. By firmly holding the lateral projections 116, a user can twist the tab 114 and remove it from the tip 106. This creates a dispensing opening 118 at the position where the joining piece 111 was attached to the hollow part of the tip 106. (See FIG. 3.) After use, the tip 106 can be resealed with the same tab 114. By turning the tab 90°, such that the lateral projections 116 are substantially parallel to the axis of the tip sidewall 110, the dispensing opening 118 can be sealed with lateral projection 116. (See FIG. 4.)

At least one of the lateral projections 116 of the tab 114 are tapered at the end 120 to create an effective seal when inserted into the opening. In the embodiment pictured, the projections are symmetrical. However, the invention also includes asymmetrical projections. It is also possible for the tab to have only one lateral projection.

The cross-sectional area of the tab 114 at the widest point, i.e. where the lateral projection 116 meets central portion of the tab, C₁, is greater than the cross-sectional area C₂ of the dispensing opening 118 at the tip 106. (See FIG. 3.) The tapered ends 120 of the lateral projections 116 easily slide into the tip 106 until the point where the cross-sectional area of the tab is equivalent to the cross-sectional area of the dispensing opening, C₂. At this point the tab 114 cannot move any further into the tip 106. (See FIG. 4.) The result is an effective seal that minimizes exposure of the container contents to air.

Another advantage of the tapered tab 114 is that the tapered end 120 of the lateral projection 116 that first slides into the tip 106 is narrow and pointed enough to help dislodge any tube contents that are stuck in the tip 106. This prevents blockage of the opening 118, resulting in greater ease in dispensing. This will also prevent contents from adhering to the sides of the tip and drying up.

When re-use of the container 100 is desired, tab 114 can be easily grasped by the joining piece 111 and pulled. The joining piece is a solid piece of material that makes up a portion of the tab 114 and provides a grip for removal of the tab 114 from the tip opening 118. Once removed, the tab 114 can be set aside or stored elsewhere until it is needed to re-seal the tip. This facilitates reuse of the container 100 by allowing repeated unsealing and resealing of the tip 106.

Thus, the present invention is a tab/plug 114 that can be easily removed by twisting the tab 114. Projections 116 on the side of the tab allow for an easy grip-and-twist removal. These projections 116 are then used to seal the tip 106 when the tab 114 is turned on its side. No scissors are required, and the tab 114 allows for a tight seal so that the container contents may be stored for later use. The elimination of the cutting requirement saves time, frustration, and possible injury. Subsequent removal of the tab 114 is easily accomplished. The joining piece 111 of the tab 114 allows a user to grip the tab 114 for removal from the opening 118.

The container 100 of the present invention can be unitarily manufactured by a compression/blow molding process. A parison is placed between the two halves of a mold cavity and as the mold halves clamp together over the parison, a portion of the parison is compressed to create the tab. The remainder of the container is subsequently blow molded to form the tip 106 and the tubular receptacle 101. Alternatively, the tab 114 with tip 106 can be integrally molded and then assembled together with a preexisting tubular receptable 101.

The container 100 can then be filled with the material to be dispensed. For example, at a filling station, the tubular receptacle 101 of the container is filled with the desired contents from the bottom end 102 of the receptacle 101. Once the contents are in the tubular receptable 101, the bottom end 102 can be flattened and heat welded. This creates a flat seal on the bottom end 102 of the receptacle 101, and allows a user to squeeze out container contents in the amount desired. Alternatively, a movable piston can be placed at the bottom of the receptacle, similar to a known caulk tube used with a caulk gun. In the latter embodiment, the bottom end 102 of the receptacle 101 would remain cylindrical in shape and open.

The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the present invention. All examples presented are representative and non-limiting. The above-described embodiments of the invention may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described. 

1. A container comprising: an elongated, tubular tip, tapered at one end; a tab having a lateral projection and a joining piece, said tab being removably connected to said tip at the tapered end, wherein the tab and tip are integrally molded.
 2. The container of claim 1, further comprising a tubular receptacle at the end of the tip, opposite to the end at which the tab sits.
 3. The container of claim 2, wherein the receptacle is adapted for containing a viscous substance.
 4. The container of claim 1, wherein the lateral projection of the tab is tapered at one end.
 5. The container of claim 1, wherein the tab has two lateral projections, at least one of which is tapered.
 6. The container of claim 1, wherein the joining piece is substantially circular.
 7. The container of claim 1, wherein the tab is adapted to create a dispensing opening in the tip once removed.
 8. The container of claim 1, wherein an axis of the tab defined by said lateral projection is substantially perpendicular to an axis of the tubular tip before removal of the tab.
 9. The container of claim 6, wherein a lateral projection of the tab is adapted to plug the tip once the tab is removed.
 10. A method comprising: (a) providing a container having a tip which is tapered at one end and a tab with a lateral projection and joining piece; and (b) removing said tab to create an opening in said tip.
 11. The method of claim 10, wherein removing the tab creates a dispensing opening in the tip.
 12. The method of claim 10, wherein a lateral projection of the tab is tapered and the method further comprises plugging the tip by inserting said lateral projection into the opening.
 13. The method of claim 10, wherein the container further comprises a tubular receptacle at the end of the tip, opposite the end at which the tab sits.
 14. The method of claim 10, wherein the receptacle is adapted for containing a viscous substance.
 15. The method of claim 14, further comprising expressing the viscous substance through the tip.
 16. A method of manufacturing a container comprising: (a) extruding a parison between two mold halves; (b) closing said mold halves; and (c) blowing air into the parison to expand the parison to produce a container that comprises: (1) a hollow tube that is tapered at one end; and (2) a tab with a lateral projection and a joining piece attached to said tab.
 17. The method of claim 16 wherein the tab is formed by compression molding when the mold halves close.
 18. The method of claim 16 wherein said tab is solid.
 19. The method of claim 16 further comprising filling said container.
 20. The method of claim 19 further comprising sealing said container. 